Extruded Aluminum Rail

ABSTRACT

An integrally formed rail for use with a fence panel. The rail is formed to define a top platform, first and second side walls, and a bottom platform. The side walls extend from the top platform and past the bottom platform. The top platform and the bottom platform define the boundaries of a rail channel. The top platform and the bottom platform define picket openings. The rail is formed by extruding the platforms and side walls from an extrudable material such as aluminum. The picket openings can be formed by inserting a mandrel in the rail channel and stamping the openings. Fence pickets are inserted through the picket openings to construct the fence panel. A retaining rod is inserted in the rail channel and through openings in the pickets to retain the pickets in the panel.

FIELD OF THE INVENTION

The present invention relates generally to rails and more particularly to rails for use with picket fences.

SUMMARY OF THE INVENTION

The present invention is directed to a rail for use with a fence. The rail is integrally formed and comprises a top platform having opposed first and second lateral edges, a first side wall which depends from the first lateral edge of the platform, a second side wall which depends from the second lateral edge of the platform, and a bottom platform disposed between the first side wall and the second side wall. The first side wall and the second side wall extend from the top platform and past the bottom platform. The top platform and the bottom platform define boundaries of a rail channel.

In an alternative embodiment, the present invention is directed to a rail for use with a fence, wherein the rail comprises a channel element. The channel element comprises a top platform having opposed first and second lateral edges, a first side wall which depends from the first lateral edge of the platform, a second side wall which depends from the second lateral edge of the platform, and a bottom platform disposed between the first side wall and the second side wall. The first side wall and the second side wall extend from the top platform and past the bottom platform. The top platform and the bottom platform define a rail channel and the bottom platform is characterized by a plurality of longitudinally spaced picket openings formed in the platform. The channel element is formed from extruded metal.

In yet another embodiment, the present invention is directed to a method of making a rail for use in a fence. The method comprising the step of forming a channel element by extrusion. The channel element comprises a top platform having opposed first and second lateral edges, a first side wall which depends from the first lateral edge of the platform, a second side wall which depends from the second lateral edge of the platform, and a bottom platform disposed between the first side wall and the second side wall such that the first side wall and the second side wall extend from the top platform and past the bottom platform. The method further comprises the steps of inserting a mandrel in the channel element between the top platform and the bottom platform, and stamping a plurality of picket openings in the bottom platform.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of a section of a fence using the rail of the present invention. The section has been shown fragmentarily to indicate indeterminate length. The supporting terrain and substrates are shown in cross section.

FIG. 2 is a top plan view showing the channel element of a rail of the present invention.

FIG. 3 is a side view showing the channel element of the rail shown in FIG. 2.

FIG. 4 is a bottom plan view showing the channel element of the rail shown in FIG. 2.

FIG. 5 is an end view showing the channel element of the rail shown in FIG. 2.

FIG. 6 is a top plan view showing the channel element of the top rail of the fence shown in FIG. 1.

FIG. 7 is a side view showing the channel element of the rail shown in FIG. 6.

FIG. 8 is a bottom plan view showing the channel element of the rail shown in FIG. 6.

FIG. 9 is an end view showing the channel element of the rail shown in FIG. 6.

FIG. 10 is an elevation view of a fence panel for use in a fence.

FIG. 11 is a partial bottom perspective view of the fence panel shown in FIG. 10.

FIG. 12 is a front elevation view of an alternative embodiment of a fence using rail of the present invention. The section has been shown fragmentarily to indicate indeterminate length. The supporting terrain and substrates are shown in cross section.

FIG. 13 is an elevation view of a fence panel for the fence shown in FIG. 12.

FIG. 14 is an end view of the panel shown in FIG. 10.

FIG. 15 is an end view of the panel shown in FIG. 10 having a retaining rod in the rails.

FIG. 16 is an end view of the panel shown in FIG. 13.

FIG. 17 is a partial exploded cutaway view of the panel of FIG. 14.

FIG. 18 is a partial exploded cutaway view of the panel of FIG. 15 showing the retainer rod.

FIG. 19 is a partial exploded cutaway view of the panel of FIG. 16.

DETAILED DESCRIPTION

With reference now to the drawings and to FIG. 1 in particular, the present invention comprises a fence, generally designated by reference numeral 10. The fence 10 preferably comprises a plurality of adjacent sections or panels, such as the sections 12 and 14. Each section comprises a pair of adjacent vertical posts 16. Preferably, the fence 10 is configured so that the same single post 16 may be shared by two adjacent sections, as shown in FIG. 1.

Preferably, the posts 16 are of identical construction. Each of the posts 16 is securely anchored at its lower portion into a substrate 18, such as an underground mass of concrete. The substrates 18 are preferably disposed in spaced relationship, with a separate substrate preferably supporting each post 16. The posts 16 are situated along the boundary of the area to be enclosed by the fence 10, with a post spacing which is adequate to impart strength to the fence 10 and to securely anchor other fence components.

Distance between posts 16, as well as height, diameter, and cross-sectional design of the posts may be varied to suit the particular application of the fence 10. Design and construction of posts 16 will preferably be comparable to that described in commonly owned U.S. Pat. No. 6,969,051, the content of which is hereby incorporated in its entirety.

With continued reference to FIG. 1, each section of the fence 10 further comprises a plurality of elongate rails 20 and vertically disposed pickets 21. Each rail 20 comprises a channel element 22. The channel element 22 is integrally formed and comprises single piece construction. Preferably the channel element 22 is formed from a strong and durable material, and more preferably from a material which is relatively lightweight and extrudable as well. Most preferably, the channel element 22 is formed in a die by an extrusion process. After the rail has been formed, a polyester powder coating is preferably provided in order to enhance the component's corrosion resistance.

Referring now to FIGS. 2-5, the channel element 22 is therein in greater detail. The channel element 22 is an elongate structure having a first end and a second end. The channel element 22 comprises an elongate planar top platform 24 and an elongate planar bottom platform 26. The top platform 24 has a first lateral edge 28 and an opposed second lateral edge 30. A first side wall 32 depends from the first lateral edge 28, and a second side wall 34 depends from the second lateral edge 30. The bottom platform 26 is disposed between the first side wall 32 and the second side wall 34 such that the bottom platform is parallel to the top platform 24. The side walls 32 and 34 extend from the top platform 24 and past the bottom platform 26.

The platforms 24 and 26 and side walls 32 and 34 define the boundaries of a rail channel 36. The first and second side walls 32 and 34 are preferably disposed in parallel planes, with each orthogonal to the planes of the platforms 24 and 26. The rail channel 36, as shown in FIG. 5 is therefore preferably substantially rectangular in cross section. Preferably, a base of each of the side walls 32 and 34, remote from the top platform 24, comprises an in-turned flange section 38. Again as shown in FIG. 5, each flange section 38 is preferably characterized by a triangular cross section, and functions to enhance the strength of the channel element 22.

Referring now to FIGS. 2 and 4, the platforms 24 and 26 each define a plurality of collinear, longitudinally spaced, picket openings 40 and 42. The picket openings 40 and 42 are preferably disposed so that the center of each picket opening 40 in the top platform 24 is aligned with the center of a corresponding picket opening 42 in the bottom platform 26. Preferably, the picket openings 40 and 42 are formed by inserting a mandrel into the rail channel 36 and then stamping the platforms 24 and 26 to create the picket openings.

With continued reference to FIG. 4, the picket openings 42 in the bottom platform 26 are preferably longer than the picket openings 40 in the top platform 24. The difference in length of the openings 40 and 42 allows for the fence 10 to be more easily used on an inclined surface. More preferably, the rail 20 further comprises a spacing insert 44 in each of the picket openings 40 in the top platform 24 of the channel element 22. The inserts 44 provide for additional support for pickets 21 (shown in FIG. 1) in the fence 10. The inserts 44 are preferably made of a strong, flexible and water-resistant polymer or other like material.

Turning now to FIGS. 6-9, shown therein is an alternative embodiment for a rail 50 for use with the present invention. The rail 50 functions to serve as a top rail for the fence 10 and provides an alternative to the rail 20 because pickets 21 (see FIG. 1) do not pass all the way through the rail. Similar to the rail 20 described above, the top rail 50 comprises a channel element 52. The channel element 52 is integrally formed and comprises a single piece elongate structure having a first end and a second end. The channel element 52 comprises a top platform 54 and bottom platform 56. A first side wall 58 and a second side wall 60 each depend from opposing lateral edges of the top platform 54. The bottom platform 56 is disposed between the first side wall 58 and the second side wall 60 such that the bottom platform is parallel to the top platform 54.

The platforms 54 and 56 and side walls 58 and 60 define the boundaries of a rail channel 62. The rail channel 62, as shown in FIG. 9, is therefore preferably substantially rectangular in cross section. Preferably, a base of each of the side walls 58 and 60 is provided with an in-turned flange section 64. Again as shown in FIG. 9, each flange section 64 is preferably characterized by a triangular cross section, and functions to enhance the strength of the channel element 52. Referring now particularly to FIGS. 6 and 8, unlike the rail 20 previously described, in the top rail 50 only the bottom platform 56 defines a plurality of collinear, longitudinally spaced, picket openings 66.

As with the rail 20 of FIGS. 2-5, the channel element 52 of the top rail 50 shown in FIGS. 6-9 is preferably formed from a strong and durable material, and more preferably from a material which is relatively lightweight and extrudable. Most preferably, the channel element 52 is formed in a die by an extrusion process. Preferably, the picket openings 66 are formed by inserting a mandrel into the rail channel 62 and then stamping the bottom platform 56 to create the picket openings. After the rail 50 has been formed, a polyester powder coating is preferably provided in order to enhance the component's corrosion resistance

Referring now to FIG. 10, shown therein is a fence panel 70 constructed with the rails 20 and 50 of the present invention. The fence panel 70 comprises a plurality of rails 20, a top rail 50, and a plurality of vertically disposed pickets 21. The pickets 21 are sized to be received through the picket openings 40 and 42. The pickets 21 are preferably tubular in construction and characterized by a substantially rectangular cross-section.

Each picket 21 for use in the panel 70 preferably defines a plurality of parallel, longitudinally offset, retainer passages 72. The number of retainer passages 72 in each picket 21 preferably equals the number of rails 20 and 50 in the panel 70. The retainer passages 72 are positioned on the pickets 21 such that each retainer passage may be aligned with corresponding retainer channels 36 and 62 of the rails 20 and 50.

The panel 70 of the present invention further comprises a plurality of elongate retainer elements 74 (shown in FIG. 18), used to connect the plurality of pickets 21 to the rails 20 and 50. The retainer elements 74 are disposed within the retainer channels 36 and 62, and received within the retainer passage 72 of the pickets 21. In the preferred embodiment, the retainer passages 72 in the pickets 21 will comprise longitudinally aligned holes in the pickets and the retainer elements 74 will comprise steel rods sized to pass through the hole passages. The retainer elements 74 function to secure the pickets 21 to the rails 20 and 50.

Pickets 21 are installed on the rails 20 and 50 by extending each picket through an aligned pair of picket openings 40 and 42 of a rail 20, until the retainer channel 36 of the rail is aligned with the retainer passage 72. With the pickets 21 in the rail 20 and the retainer passage 72 aligned in the retainer channel 36, the retainer element 74 is inserted into the channel and through the aligned retainer passages of each of the pickets. This procedure is repeated for each rail 20 and 50 to be used in a panel. Preferably, construction of the panel 70 will be comparable to that described in U.S. Pat. No. 6,969,051, previously incorporated by reference.

With reference again to FIG. 1, the fence panel 70 is shown installed as part of the fence 10. As installed, the panel 70 extends between an adjacent pair of posts 16 comprising a section of the fence 10. Posts 16 are disposed at opposing ends of the panel 70 and, consequently, opposing ends of the rails 20 and 50. Preferably, at least two rails 20 and 50 extend between each adjacent pair of posts 16. While any plural number of rails 20 and 50 may be provided for each section, either three rails, as shown in FIG. 1, or two rails, as shown in FIG. 12, are preferred. The length of each rail 20 should be sufficient to fully span the distance between the adjacent of pair of posts 16 which will support that rail 20.

Various means and hardware for connecting fence panels 70 and rails 20 and 50 to posts 16 may be used. Additionally, other hardware components for protecting internal components of the fence 10 and fence panels 70 may be used as desired. Components and hardware suitable for use with the present invention are disclosed in previously mentioned U.S. Pat. No. 6,969,051.

Referring now to FIG. 12, shown therein is another embodiment of the fence of the present invention, generally designated by reference number 80. Similar to the fence 10 shown in FIG. 1, each section of the fence 80 of the present embodiment is formed of a pair of adjacent vertical posts 16, which support a fence panel 82 at a plurality of parallel rails 20. Shown in FIG. 13, the fence panel 82 comprises only two rails, an upper rail 84 and a lower rail 86. The upper rail 84 and lower rail 86 are identical in construction to the rail 20 described with reference to FIGS. 1-5. As these rails 84 and 86 allow pickets 88 to pass through the rails, the pickets terminate above the upper rail 84.

The fence of the present invention may be assembled from, and the methods of the invention advantageously practiced with, a kit. The kit of the present invention preferably comprises a plurality of posts, preferably identical to the posts 16. The posts 16 are preferably provided in a number sufficient to form the fence, or section thereof, to be installed.

The kit further comprises a plurality of rails 20, with each rail 20 including a channel element 22 and a retainer element 74. The rails 20 should be provided in the kit in a number sufficient to form the fence, or fence panels thereof, to be installed. The kit should further comprise a plurality of brackets and fasteners should for securing each rail 20 to an adjacent pair of posts 16. The brackets and fasteners are preferably provided in a number sufficient to form the fence, or section thereof, to be installed.

The kit further comprises a plurality of pickets, preferably identical to the pickets 21, preferably in a number sufficient for the fence, or section thereof, to be installed.

Various modifications can be made in the design and operation of the present invention without departing from the spirit thereof. Thus, while the principal preferred construction and use of the invention have been explained in what is now considered to represent its best embodiments, it should be understood that the invention may be practiced otherwise than as specifically illustrated and described, and claimed in the following claims. 

1. A rail for use with a fence, the rail comprising: a top platform having opposed first and second lateral edges; a first side wall which depends from the first lateral edge of the platform; a second side wall which depends from the second lateral edge of the platform; and a bottom platform disposed between the first side wall and the second side wall, such that the first side wall and the second side wall extend from the top platform and past the bottom platform; wherein the top platform and the bottom platform define boundaries of a rail channel; and wherein the rail is integrally formed.
 2. The rail of claim 1 further comprising: a first flange at an end of the first side wall remote from the top platform; and a second flange at an end of the second side wall remote from the top platform.
 3. The rail of claim 1 wherein the bottom platform defines a plurality of longitudinally spaced picket openings formed therein.
 4. The rail of claim 1 wherein the top platform defines a plurality of longitudinally spaced picket openings formed therein; and wherein the bottom platform defines a plurality of longitudinally spaced picket openings formed therein; such that each picket opening of the top platform is aligned with a corresponding picket opening in the bottom platform.
 5. A fence panel comprising a plurality of rails as defined in claim 4, and further comprising: a plurality of vertically disposed pickets, each picket passing through an aligned pair of picket openings in the top platform and the bottom platform of each of the plurality of rails.
 6. The rail of claim 4 further comprising an elongate retainer element receivable within the rail channel.
 7. A fence panel comprising a plurality of rails as defined in claim 6, and further comprising: a plurality of vertically disposed pickets, each picket passing through an aligned pair of picket openings in the top platform and the bottom platform of each of the plurality of rails; and wherein each picket defines at least one retainer passage; the retainer element of each rail positioned within the rail channel such that it passes through the retainer passages of the pickets.
 8. A fence comprising a plurality of fence panels as defined in claim 7, and further comprising: a plurality of vertically disposed posts, each adjacent pair of posts supporting opposite ends of a plurality of rails.
 9. A kit comprising a plurality of rails as defined in claim 1, and further comprising: a plurality of posts; and a plurality of pickets.
 10. A kit comprising a plurality of rails as defined in claim 4, and further comprising: a plurality of posts; and a plurality of pickets.
 11. A method of making a rail as defined in claim 1, comprising: forming the rail from an extrudable material by an extrusion process.
 12. A method of making a rail as defined in claim 4, comprising the steps of: forming the rail from an extrudable material by an extrusion process; inserting a mandrel into the rail channel; stamping the plurality of picket openings in the top platform; and stamping the plurality of picket openings in the bottom platform.
 13. The method of claim 12 in which the extrudable material comprises aluminum.
 14. A method of making a rail as defined in claim 2, comprising the steps of: forming the rail from an extrudable material by an extrusion process; inserting a mandrel into the rail channel; and stamping the plurality of picket openings in the bottom platform.
 15. The method of claim 14 in which the extrudable material comprises aluminum.
 16. A fence comprising a plurality of rails, including at least one rail as defined in claim 15, and further comprising: a plurality of vertically disposed posts, with each adjacent pair of posts supporting the opposite ends of a plurality of rails; and a plurality of pickets, with each picket being laterally traversed by at least one retainer passage; in which the retainer element is positioned within the retainer channel such that it passes through the aligned retainer passages of the pickets.
 17. A rail for use with a fence, the rail comprising: a channel element comprising: a top platform having opposed first and second lateral edges; a first side wall which depends from the first lateral edge of the platform; a second side wall which depends from the second lateral edge of the platform; and a bottom platform disposed between the first side wall and the second side wall, such that the first side wall and the second side wall extend from the top platform and past the bottom platform; wherein the top platform and the bottom platform define a rail channel; and wherein the bottom platform is characterized by a plurality of longitudinally spaced picket openings formed therein; and wherein the channel element is formed from extruded metal.
 18. The rail of claim 1 further comprising: a first flange at an end of the first side wall remote from the top platform; and a second flange at an end of the second side wall remote from the top platform.
 19. The rail of claim 1 wherein the top platform is characterized a plurality of longitudinally spaced picket openings formed therein.
 20. A method of making a rail for use in a fence, the method comprising the steps of: forming a channel element by extrusion, the channel element comprising: a top platform having opposed first and second lateral edges; a first side wall which depends from the first lateral edge of the platform; a second side wall which depends from the second lateral edge of the platform; and a bottom platform disposed between the first side wall and the second side wall, such that the first side wall and the second side wall extend from the top platform and past the bottom platform; inserting a mandrel in the channel element between the top platform and the bottom platform; stamping a plurality of picket openings in the bottom platform.
 21. The method of claim 18 further comprising stamping a plurality of picket openings in the top platform. 